Insole blank and method of making insoles therefrom



Sept. 20, 1938. A. c. sEWALI. 2,130,968

INsoL-E BLANK AND METHOD 0F MAKING INsoLEs THEREFROM Filed Jan. 3, 19382 Sheets-Sheet l 2 Sheets-Sheet 2 A. C. SEWALL INSOLE BLANK AND METHODOF MAKING INSOLES THEREFROM Filed Jan. 5, 1938 sept. 2o, 1938.

Patented Sept. 20, 1938 INSOLE BLANK AND METHOD F MAKING INSOLESTHEREFROM Arthur C. Sewall. Auburn, Maine Application January 3, 1938,Serial No. 182,952

21 Claims.

My invention relates to insoles, and methods of and materials for makingthe same.

This application is a continuation-in-part of applicants co-pendingallowed application Serial Number 88,152, med Juneso, 1936.

The invention, which has among its objects the provision of insoles ofimproved construction,.and methods of and strips for making the samewith a minimum waste of material, will be best understood from thefollowing description when read in the light of the accompanyingdrawings, the scope of the invention being more particularly pointed outin the appended claims. In the drawings: y Figure 1 is a plan view of afragment of a strip from which the insoles are made, this ligure alsolschematically showing a way in whichv the insoles may be cut from thestrip;

Fig. 2 is a section on the line 2-2 of Fig. 1;

Fig. 3 is a plan of the insole;

Fig. 41s a side elevation of the insole according to Fig. 3;

Fig. 5 is a plan view of a fragment oi a modifled form of strip fromwhich a modified form of insole may be made, this figure also showing away in which the modified insoles may be cut from lthe strip;

Fig. 6 is a section on the line 6-6 of Fig. 5;

Fig. 7 is a plan of the modified form of insole; and Y Fig. 8 is a sideelevation'of' the insole according to Fig. 7.

It has been found that womens and other light weight shoes of the McKay,Littleway and similar types may be more easily formed and are moresatisfactorywhen in use when the bail or ball and toe portions of theinsole are of flexible material. However, if the shank and heel por-4suitable for the purpose, commonly would be formed of a sheet ofmaterial, such as stiff leather,

the outline of lwhich -conforms to the outline of the shank and heelportions of the insole, and would be laid upon the llexible insole andassembled with it in the shoe. Y, Referring particularly to Figs. 1 to4.of the drawings, applicant has foundthat improved results can besecured,'particularly with a so-called long shankf type of insolel usedwith FrenchA (c1. 12a-14s) and Louis heels, by making the ball portion Iand toe portion 3 ofa sheet of thin, flexible material, such as alphacellulose fibers felted together to make a bibulous paper which isafterward impregnated with rubber in the form of 5 a hydrocarbon rubbersolution or a natural or artificial rubber dispersion such as thenatural rubber dispersion known at latex, while the shank portion 5 andheel portion 1 are made of a sheet of stiif, preferably hard, cellulosematerial such 10 as berb'oard. Conveniently the toe portions of theinsole are of the same thickness, or approximately so, and are securedtogether with rubber cement at a wide, skived joint 9.

i An insole so constructed presents a forward Il portion II of flexiblematerial, which insole is much tougher than one having that portion madeof ,upper leather or the like, and presents a rearward portion I3 ofstiff, hard material which is much stiffer and harder than sole leather20 of the same thickness. Further, each portion of the insole mayreadily be made of the same thickness, and a vplurality of insoles mayreadily be made of uniform thickness and properties, thusentirelyavoiding the necessity of skiving vleather zo.

to a given thickness in the attempt to make insoles of uniform thicknessand properties, which leather when skived is usually seriously deficientin tensile strength, stiffness and hardness. l

In th'e preferred way of making the insoles ac-v 30 cording to Figs. 3and 4 by the improved method a strip is formed having a central orintermediate band I5 of the material of which the rearward -portions I3of theinsoles are formed. Ce-

mented to the opposite edges of this central band 35 -I by means ofskived joints I1 are side bands I9 of the :material of which theforwardportions II of the insoles are formed. From this strip so formedto provide relatively fiexible and stiff zones are cut Athe'insoles,preferably by use of 40 the machine which will die or cut by a stampingoperation a plurality of insoles at a time as the strip is fed throughthe machine. ,The dotted lines 2i in Fig. 1 indicate the portions'of thestrip which may be cut to form the insoles. \l3y cutting 4.5 from thestrip a row of insoles, so positioned that alternate insoles have theirforward portions II cut from opposite side bands I9 of the strip, whileall the rearward portions I3 are cut from the central band on outlinesin llongitudinal overvai() lapping relation, a great saving in materialcan be effected. Preferably the insoles are so cut 1 that the' width Abetween the heel portions of adiacent insoles is less than the width Bof those lportions and slightly greater than the width C mi-v,

of the shanks, which permits the shanks to be cut from such portions ofwidth A, and thus cutting the insoles on outlines in lateral overlappingrelation eifects a decided saving in material.

If desired the toe portion of the insole may also be or relatively stiftmaterial such as ilberboard as shown by the insole according to Figs. 'Iand 8. 'I'his insole is exactly like that shown by Figs. 3

' .and 4 'except that only the ball portion I is oi.'

the relativelydlexible material, the toe portion 23. of relatively stiimaterialbeing joined to the forward end of the ball portion by Kacemented, wide, skived joint 25.

A form of strip for use in making the insole according to Figs. 7 and 8is shown by Figs. 5 and 6. 'I'his strip has a central or intermediateband 21 of the relatively stiff material of which the rearward portionsI3 of the' insoles are formed. Cemented to opposite edges ofthis'central band by means of skived joints 29 are bands 3| of therelatively flexible material of whichthe ball portions of the insolesare formed, which 'cemented to the outer edges of the bands 2| by meansof like joints 29 are bands 33 of the relatively stiff material of whichthe toe portions are formed. The insoles may be cut along the dottedlines from the strip so formed as indicated in Fig. 5.

It will be observed that each of the strips above described has betweenits edges a longitudinally extending zone of the relatively stiffmaterial from which the combined shank and heel' portions are cut, thiszone being of widthapproximately the combined `lengths of thoseportions, and that contiguous with each edge of said zone is a zone ofthe relatively flexible material of which the ball portion is formed,these last mentioned zones being of width at least approximately thelength of the ball portions of the insoles.

It will be understood that within the scope of the appended claims widedeviations may be made from the above described strips and insoles, andmethods of and materials for making the insoles, :irithout departingfrom the spirit of the inven- 1. The method of forming a multiplicity ofinsoles having relatively stii heel and shank portions and relativelyexible ball portions which comprises forming a sheet having a zone ofthe material of which the heel and shank portions are formed, and, at,each of opposite sides of said zone .and contiguous therewith, zones ofthe material of which said ball portions are formed, and cutting fromsaid sheet a multiplicity of the insoles in such wise that the heel andshank portions of all said insoles so cut are formed of the rstmentioned zone whilelthe ball portions of adjacent insoles are formed ofthe zones at opposite sides respectively of said rst mentioned zone.

2. The method according to claim 1 in which the heel and shank portionsof the insoles are cut from the sheet on outlines in longitudinaloverlapping relation. v

3.,'I'he method of forming a multiplicity'of insoles having relativelyilexible ball and toe portions and relatively stiff heel and shankportions which comprises forming a sheet having a ball and toe portionsoi' adjacent insoles so cut are formed of the zones at opposite sidesrespeci tively oi the ilrst mentioned zone while the heel and shankportions of all said insoles are cut from said iirst mentioned zone.

4. The method according to claim 3 in which the heel and shank portionsoi the insoles are cut from the sheet on outlines in longitudinaloverlapping relation. y

5. The method according to claim 3 in which the heel and shank portionsof the insoles are cut from the sheet on outlines in longitudinal andlateral overlapping relation with the spaces onv the rst mentioned zonebetween the portions thereof forming the heel portions of alternateinsoles'so cut being narrower than said heel portions but being at leastthe width of the shank portions of said insoles.

6. 'Ihe method of forming a multiplicity of insoles having relativelystiiI toe, shankA and heel portions and relatively flexible ballportions which comprises forming a sheet having a zone of the lmaterialof which said heel and shank portions are formed, and, at each ofopposite sides of said zone and contiguous therewith, zones of thematerial of which said ball portions are formed, and, at that side ofeach oi the last mentioned zones which is opposite the nrstmentioned'zone and contiguous with such side, a zone of the material ofwhich said toe portions are formed, and cutting from said sheet amultiplicity of the insoles in such wise that the heel and shankportions of all insoles so cut are formed of the material of said rstmentioned zone while the ball and toe portions oi.' adjacent insoles areformed of the zones at opposite sides respectively of said rst mentionedzone.

7. The method according to claim 6 in which the heel and shank portionsof the insoles are cut from the sheet on outlines in longitudinaloverlapping relation.

8. The method according to claim 6 in which the heel and shank portionsof the insoles are cut from the sheet on outlines in longitudinal andlateral overlapping relation with the spaces on the first mentioned zonebetween the portions thereof forming the heel portions of alternateinsoles so cut being narrower than said heel portions but being at leastthe width of the shank portions of said insoles.

9. The method of forminga multiplicity of insoles having relativelyflexible ball portions and relatively sti heel and shank portions whichcomprises forming a sheet having a zone of the material of which saidheel and shank portions are formed, and, at each of opposite sides ofsaid zone and contiguous therewith, zones of the material of which saidball portions are formed, and cutting from said sheet a multiplicityoi.' the insoles from closely adjacent portions of the sheet in suchwise that Vthe ball portions of adjacent ins'oles so cut are lformed ofthe zones at opposite sides respectively of the rst mentioned zone whiletheheel and shank portions of all said insoles are cut 4from said ilrstmentioned zone on outlines in longitudinal and lateral overlappingrelation with the spaces on said ilrst mentioned zone between theportions thereof forming the heel portions oi alternate insoles so cutbeing narrower than said heel portions but being Yat least the width ofthe shank portions of said insoles.

10. An article of manufacture comprising a sheet suitable as a blank fora multiplicity of insoles having, between its opposite edges, arelationed zones being at least the length of an insole and the'width ofsaid first mentioned zone being at least the length of the heel portionof the insole.

11. The article accordingto claim 10 in which the rst. mentioned zone isof width approximately the' combined lengths of the heel and shankportions of the insole and comprises a band of relatively stiff, hardiiberboard coextensive with the width of said zone, the other zonesconsisting of rubber impregnated sheet material of felted cellulosefibers.

12. An article of manufacture comprising a sheet suitable as a blank fora multiplicity of insoles having an elongated band of stiff, hardfiberboard, and, united thereto at each side thereof, elongated bands ofrubber impregnated, flexible sheet material consisting of feltedcellulose fibers.

13. An article of manufacture comprising a sheet suitable as a blank fora multiplicity of insoles having an elongated band of stiff, hardberboard, and, united thereto at each side thereof, elongated bands ofsubstantially the same thickness as the rst mentioned band formed ofrubber impregnated, exible sheet material consisting of felted cellulosefibers.

14. An article of manufacture comprising asheet of substantially uniformthickness suitable as a blank for a multiplicity of insoles having anelongated band of relatively stiif, hard fiberboard, and, cementedto,said band at opposite edges thereof 'by means of skived, overlappingjoints, elongated bands of substantially the same thickness as the firstmentioned band consisting of relatively flexible, rubber impregnatedsheets of felted cellulose fibers, the combined Widths of saidflberboard band and either of the' other bands being at least the lengthof an insole, and

. said berboard band being of Width approximately the combined lengthsof the heel and shank portions of the insole.

15. I.An article of manufacture comprising a sheet suitable as a blankfor a multiplicity of insoles, having, between its opposite edges, arelatively stiff zone, and, at each of opposite sides of said zone andcontiguous therewith, a rela#- tively exible zone, and, at that side ofeach of the last mentioned zones which is opposite the first mentionedzone. and contiguous with such side, a relatively stiff zone, thecombined widths of the first mentioned zone and the two mentioned zonesat either side thereof being at least the length of an insole, the widthof the first mentioned zone being approximately the coni--` binedlengths of the heel and shank portions of an insole, and the width ofeach of the second mentioned zones being approximately the length of theball portion of the insole.

16. The article accoding to claim 15 in winch each relatively stiff zonecomprises a band of.

relatively stiff, hard flberboard coextensive with the width of thezone, and the relatively exible zone consists of a bandv of rubberimpregnated sheet material of -felted cellulose fibers coexte'ninsoleseach of which has a relatively stiff portion that includes one endportion of the insole, and an adjacent relatively flexible portion,which sheet between itsopposite edges has a relatively stiff zone, and,at each of opposite sides of said zone, a relatively flexible zone, vthecombined widths of said relatively stiff zone and either of saidrelatively flexible zones being not less than the length of an insole;said zones being of such width, respectively, that when two such insolesare superimposed on said sheet transversely of said zones, with theinsole toes pointing in opposite directions, and the regions ofdemarcation between their relatively stiff and flexible portionsrespectively superimposed on the corresponding regions of said sheet atopposite sides of said relatively stiff zone, their relatively stiffportions will materially overlap and their ball portions will beincluded by said relatively flexible zones.

18. The article according to claim 17 in which the first mentionedrelatively stiff zone is of width approximately the combined lengths ofthe heel and shank `portions of the insole, and the relatively exiblezones are each of width at least the combined lengths of theball and toeportions of the insole.

19. An article ofl manufacture comprising a sheet suitable as a blankfor a multiplicity of insoles, each of which has a relatively stiffportion that includes an end portion of the insole,

` thereof being not less than the length of an insole, said first andsecond mentioned zones being of such -width, respectively, that when twoof such insoles are superimposed on said sheet transversely of saidzones, with the insole toes 'pointing in opposite directions, and theregions of demarcation between the relatively stiff and relativelyexible portions thereof respectively superimposed on the correspondingregions of said sheet' at opposite sides of the -rst mentionedrelatively stiff zone, their relatively stiff portions included by saidrst mentioned zone will materially overlap and their ball portions willbe included by said relatively flexible zones.

20. The article according to claim 19 in which I the first mentionedrelatively stiff zone is of width approximately the combined lengths ofthe heel vand shank portions of the insole, and the second mentionedrelatively stiff zone has a width at least the length of the toe portionof the insole and is spaced from the first mentioned relatively sti zonea distance approximately the length of the ball portion of the insole.

21. The article according to claim 19 in which there is a relativelystiff zone at the side of each of said relatively flexible zonesopposite the rst mentioned relatively stiff zone and the latter is ofwidth approximately the combined lengths of the heel and shank portionsof the insole, said iiexible zones being of width approximately thelength of theball portion of the insole. r

AI2,130,968.---Arthw C. Sewall, Auburn, Maine. INsoLE BLANK AND METHOD0F MAKING INsoLEs THEREFROM. Patent dated September 20, 1938. Disclaimerfiled June 5, 1941, by the inventor.

' Hereby makes the following disclaimer:

Under claims 1, 3, and`6 he disclaims from thescope of said claims anymethod, if such be in law comprehended by said claims in their presentform, other than one wherein the first mentioned zone is formed of awidth at least equal to, but much less than twice, the length of theheel and shank portion, and the widest portion, B, of the heel of eachinsole is cut from material between the heel and shank portions of theadjacent insoles at either side thereof. i

Under claim 10 he disclaims from the scope of said claim all sheets, ifsuch be in law comprehended by said claim in its present form, otherthan those wherein the stiff zone is of a width much less than twice thelength of .the heel and shank portion y of the insole, whereby wheninsoles are cut with the toes of alternate insoles directed'respectively toward the opposite sides of the sheet the heel o f each ofthem may be cut from material between the heel and shank' portions ofthe adjacent insoles at either side thereof; j L,

Under claims 12 and 13 he disclaims from the' scope of said claims allsheets, if

I" such be in law comprehended b said claims in their present form,other than those wherein the elongated band of erboard is of a width atleast equal to, but much less than twice, the length of the heel andshank portion of such an insole ,whereby when insoles are cut with thetoes of alternate insoles directed respectively toward the oppositesides of the sheet the heel of each'of them may be cut from materialbetween the heel and shank portions of the adjacent insoles at eitherside thereof.-

, [Oficial Gazette June 24, 1941|l

